Battery powered flat tensioner tool

ABSTRACT

A tool for tensioning a strap around a load and a method of operating the tool are provided. The tool includes a housing having a gripping portion, a power supply, a motor disposed within the housing, a tensioner head having a drive shaft driven by the motor, a tension feed wheel rotatable with the drive shaft and a nosepiece rotatably mounted to the tensioner head. The nosepiece includes a strap feed path and a tension foot having a substantially planar load engaging surface. A clutch plug is secured to the tension foot opposed from the feed wheel. A biasing element urges the nosepiece in a predetermined direction relative to the tensioner head. An operating handle is coupled to the tensioner head and nosepiece and is configured to rotate the tensioner head and nosepiece relative to one another in a first direction against a force from the biasing element.

CROSS-REFERENCE TO RELATED APPLICATION DATA

This application claims the benefit of and priority to Provisional U.S. patent application Ser. No. 62/183,568, filed Jun. 23, 2015, the disclosure of which is incorporated herein in its entirety.

BACKGROUND

Strapping material is used in a wide variety of applications to secure or bundle loads. The strap material is typically metal or plastic and can be applied and tensioned around the load using either a manual or an automatic tensioning tool or tensioner. In one use, a loop of strap material is positioned around a load with a crimp seal loosely placed around the overlying courses of strap material. The tensioner is then used to draw tension in the upper strap course by positioning the crimp seal at the nosepiece of the tool and drawing the upper strap course.

Manual tensioners use a manual lever or handle operably connected to a tension wheel to draw tension in the strap and to hold tension as a seal is made in the strap. Although manual tensioners function well, they require manual operation. This can be a labor intensive undertaking and can, when carried out numerous times in a day, be very fatiguing. Moreover, the position or orientation of the strap or load may make using a manual tensioner awkward or difficult, especially after repeated uses.

Automatic tensioners are known that use pneumatic circuits to drive a tension wheel to tension the strap. While such tensioners function well, a source of compressed gas, such as compressed air, must be available for operation of the tool. Thus, such a tool has limited use when needed in a location that does not have a compressed air source readily available. Tension is typically controlled by adjusting air pressure from the supply.

Accordingly, there is a need for a powered strap tensioner having a flat foot for engaging a load or package to be bundled to produce a substantially flat, tensioned strap in the region of a strap seal. Desirably, such a tensioner is portable and can be used anywhere as needed. More desirably still, such a tensioner is powered by an on-board source and may optionally operate through an automatic tensioning cycle.

SUMMARY

According to one aspect, there is provided a tool for tensioning a strap around a load. The tool includes a housing having a gripping portion formed on an exterior surface, a power supply, a motor disposed within the housing and operably connected to the power supply, and a tensioner head positioned at one end of the housing. The tensioner head includes a drive shaft operably connected to and configured to be driven by the motor. The tool further includes a tension feed wheel mounted on and configured to rotate with the drive shaft, a nosepiece and an operating handle. The nosepiece is rotatably mounted to the tensioner head and includes a strap feed path configured to receive overlapping plies of a strap. The nosepiece also includes a tension foot having a substantially planar load engaging surface configured to engage a substantially flat surface of the load. A clutch plug is secured to the tension foot such that a portion of the strap feed path is formed between the tension feed wheel and the clutch plug. A biasing element urges the nosepiece in a predetermined direction relative to the tensioner head. The operating handle is coupled to the tensioner head and nosepiece. The operating handle is actuated to rotate the tensioner head and nosepiece relative to one another in a first direction against a force from the biasing element to increase a gap between the tension feed wheel and the clutch plug to receive overlapping plies of the strap.

According to another aspect, there is provided a method of operating a tool for tensioning a strap around a load, the tool having a nosepiece including a tension foot with a substantially planar load engaging surface. The method includes receiving, at a controller, a first signal from a strap sensing sensor that a strap is positioned in a strap feed path of the tension foot, receiving, at the controller, a second signal from a home position switch indicating that the home position switch has changed from a first state to a second state, and operating, by the controller, the motor to drive a drive shaft and rotate the tension feed wheel to tension the strap around the load in response to receipt of the first and second signals.

According to still another aspect, there is provided a nosepiece for a strap tensioning tool having a housing, a power supply, a motor disposed in the housing, and a tensioner head having a drive shaft and a tension feed wheel mounted on the drive shaft. The nosepiece includes a pivot pin configured to rotatably couple the nosepiece to the tensioner head and a tension foot having a strap feed path configured to receive overlapping plies of a strap and a substantially planar load engaging surface. The nosepiece also includes a clutch plug positioned in the tension foot substantially opposed to the tension feed wheel, the clutch plug configured to engage a strap.

These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a tool for tensioning a strap around a load or package according to an embodiment described herein;

FIG. 2 is a side view of the tool of FIG. 1 tensioning a strap extending around the load or package;

FIG. 3 is a perspective view showing a variation of the tool of FIG. 1 together with a strap for tensioning around the load or package according to an embodiment described herein;

FIG. 4 is a side view of the tool of FIG. 3 tensioning a strap extending around the load or package;

FIG. 5 is a rear view of a tensioner head and nosepiece of the tool of FIG. 3; and

FIG. 6 is a perspective view of a modular cutter attachment for the tool of FIGS. 1-5, according to an embodiment described herein.

DETAILED DESCRIPTION

While the present device is susceptible of embodiment in various forms, there is shown in the figures and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the device and is not intended to be limited to the specific embodiment illustrated.

FIG. 1 is an exploded view of a tool 10 for tensioning a strap around a load or package according to an embodiment described herein. FIG. 2 is a side view of the tool 10 of FIG. 1 in use with a strap S. Referring to FIGS. 1 and 2, the tool 10 includes, generally, a housing 12, a powertrain 14 disposed at least partially in the housing 12, a motor 16 disposed at least partially in the housing 12, the motor 16 connected to and configured to drive the powertrain 14, a power supply 18 such as a battery or battery pack, a tensioner head 20 operably connected to the powertrain 14, a nosepiece 22 and an operating lever 24 operably mounted to the tensioner head 20 and the nosepiece 22.

In one embodiment, the housing 12 includes a substantially longitudinally extending bore in which the powertrain 14 and motor 16 are positioned. The housing 12 may also include an opening at a first end 26 through which the powertrain 14 is connected to the tensioner head 20. The powertrain 14, motor 16 and opening may be substantially aligned axially.

The power supply 18 may be operably connected to the housing 12 either in a chamber configured to receive the power supply or at an external surface area of the housing 12. The power supply 18 may be either removably or fixedly secured to the housing 12.

A gripping portion 30 is formed on an exterior surface of the housing 12. The gripping portion 30 is configured to be grasped by a user's hand to manipulate or operate the tool 10. In one embodiment, the housing 12 may be formed by first and second sections 32, 34 secured to one another using known, suitable fasteners, such as, but not limited to, screws, bolts, clips, detents, interference fit mechanisms, or a combinations thereof.

The motor 16 is operably connected to the powertrain 14, which is in turn connected to the tensioner head 20. The tensioner head 20 may include a gear train in a gear housing or gear box 36, driven by the powertrain 14. The tensioner head 20 also includes a drive shaft 38, driven to rotate by the powertrain 14 via the gear box 36. A tension feed wheel 40 is mounted to the drive shaft 38 so as to rotate with the drive shaft 38. In one embodiment, an inner circumference of the tension feed wheel 40 may be keyed to an outer circumference of the drive shaft 38 to rotate therewith. In another example, the tension feed wheel 40 may be secured to the drive shaft 38 using a suitable fastener or fastening techniques, including, but not limited to, a threaded set pin or ball detent.

As detailed above, the power supply 18 may be, for example, a battery or battery pack. The battery 18 may be, for example, a lithium-ion or nickel cadmium battery having an operational voltage of about 14.4 to 24 volts inclusive. The power supply 18 is electrically connected to the motor 16 to power the motor 16 and drive the powertrain 14, gear box 36, drive shaft 38 and tension feed wheel 40. Accordingly, the tool 10 may operate as a portable tool free from connections (e.g., power cords or pneumatic hoses) to fixed power supplies.

The nosepiece 22 is movably mounted on the tensioner head 20. The nosepiece 22 includes a tension foot 42 having a load engaging surface 44, a strap feed path 46 and clutch plug 48. In one embodiment, the tension foot 42 is pivotably mounted to the tensioner head 20, for example, with a pivot pin 50. The tension foot 42 may be urged in a first direction with one or more biasing elements 52. In one embodiment, the biasing element 52 may include one or more torsion springs positioned between the tension foot 42 and the tensioner head 20.

In one embodiment, the load engaging surface 44 is formed as a substantially flat or planar surface on a side of the tension foot 42 facing away from the housing 12. The load engaging surface 44 is configured to engage a substantially flat surface of a load or package, such as side panel of a box or container. In one embodiment, the load engaging surface 44 may be formed as an entirety of an underside of the tension foot and may be planar in its entirety. That is, the entirety of the load engaging surface 44 may lie in a single plane.

The strap feed path 46 may be formed, at least in part, as a slot or groove extending through the tension foot 42. The strap feed path 46 is configured to receive, for example, overlapping portions or plies of a strap S (see FIG. 2) such as a leading end portion L and a trailing end portion T. The strap feed path 46 extends between the clutch plug 48 and the tension feed wheel 40. In one embodiment, the strap feed path 46 may extend substantially parallel along either a portion or an entirety of its length to the load engaging surface 44.

In one embodiment, the tension foot 42 may include an arm 54 pivotably secured to the body tensioner head 20 via the pivot pin 50 and a base 56 extending from the arm 54. The load engaging surface 44 may be formed on one side the base 56. The strap feed path 46 may be formed, at least in part, on a second side of the base 56 opposite to the first side. The strap feed path 46 may also extend through a portion of the arm 54.

The clutch plug 48 is positioned on the tension foot 42. In one embodiment, the clutch plug 48 is partially positioned in the base 56 of the tension foot 42. The clutch plug 48 may include a friction surface configured to engage one ply of the strap S in the strap feed path 46 to substantially hold the ply against movement during tensioning of the strap S as another ply is driven by the tension feed wheel 40. The friction surface may be formed by a roughened or high friction surface such as a plurality of teeth. Alternatively, the friction surface may be formed from a friction material, such as rubber.

In one embodiment, one ply of the strap S may be the trailing end portion T and another ply may be the leading end portion L. The leading end portion L may be disposed under the trailing end portion T in the strap feed path 46 such that the tension feed wheel 40 engages and drives the trailing end portion T to tension the strap S and the clutch plug 48 engages the leading end portion L to hold it substantially against movement while the trailing end portion T slides relative thereto during tensioning.

The tool 10 may further include a side plate 58. The side plate 58 is affixed to the tensioner head 20 by, for example, one or more suitable fasteners. The side plate 58, together with the tensioner head 20 and tension foot 42 are configured to at least partially enclose internal components of the nosepiece 22.

FIG. 3 is a perspective view showing a variation of the tool 10 of FIGS. 1 and 2, according to an embodiment described herein. FIG. 4 is a side view of the tool of FIG. 3. Referring to FIGS. 3 and 4, the tool 10 may further include a strap guide 59. The strap guide 59 may be secured to the nosepiece 22 using a suitable fastener or fasteners, such as a bolt, screw or the like. In one embodiment, the strap guide 59 may be positioned at a rear end of the nosepiece 22. The strap guide 59 may be adjustable and is configured to maintain the strap S under the tension feed wheel 40.

FIG. 5 is a rear view of the tensioner 20 and the nosepiece 22 showing the strap guide 59. Referring to FIGS. 3-5, the strap guide 59 may include a tab 59 a to laterally guide the strap S and maintain the strap S under the tension feed wheel 40.

The operating lever 24 is operably connected to the tensioner head 20 and the tension foot 42. In one embodiment, as shown in FIG. 1, the operating lever 24 is positioned at a first side of the housing 12 proximate to the gripping portion 30, so that a user may simultaneously grasp the tool 10 and the operating lever 24. However, the present disclosure is not limited to this configuration. For example, the operating lever 24 may be positioned at a second side of the housing 12 proximate to the gripping portion 30. The first side may be, for example, an underside, and the second side may be a top side of the housing 12.

The operating lever 24 may be operably connected to the tension foot 42 of the nosepiece 22, for example, by a cam or direct contact with a portion of the tension foot 42. Rotation of the operating lever 24 causes the tension foot 42 to rotate in a second direction, opposite to the first direction, against the biasing element 52. Rotation of the tension foot 42 in the second direction causes the clutch plug 48 to move away from the tension feed wheel 40, increasing a gap between the clutch plug 48 and tension feed wheel 40. Accordingly, the clutch plug 48 and tension feed wheel 40 may be spaced apart to either disengage the strap S or receive the strap S therebetween.

It is understood that the first and second rotational directions refer to a relative rotation between the nosepiece 22 and the tensioner head 20. For example, rotation of the operating lever 24 may cause the nosepiece 22 to rotate relative to the tensioner head 20 in the second direction and the force from the biasing element 52 rotates the nosepiece in the first direction. However, the nosepiece 22 may be held against rotation when engaged with a load or package bundling. Thus, rotation of the operating lever 24 may cause the tensioner head 20 (and housing 12) to rotate relative to the nosepiece 22, and the biasing element will cause the tensioner head 20 (and housing 12) to rotate in the opposite direction relative to the nosepiece 22 upon release of the operating lever 24.

Referring again to FIGS. 1 and 2, a trigger 60 or actuation switch may be located on the housing 12. In one embodiment, the trigger 60 can be an electronic switch that is configured as a multi-function switch. The trigger 60 is operably connected to the motor 16 so that actuation of the trigger 60 may start or stop to the motor 16 to operate the tool 10. In one embodiment, the trigger 60 may be connected directly to the motor 16. In some embodiments, upon actuation of the trigger 60, the motor 16 may be powered for a predetermined amount of time or until a desired a strap tension is reached.

The tool 10 may optionally include a controller 62. The controller 62 may be positioned in the housing 12. In one embodiment, the trigger 60 may be operably connected to the controller 62, such that the controller 62 may receive a signal upon actuation of the trigger 60 and control the motor 16 in response to actuation of the trigger 60. For example, the controller 62 may start or stop the motor 16. In addition, actuation of trigger 60 may change operating modes of the tool 10, for example, between an automatic mode and a manual mode, via the controller 62.

In some embodiments, the tool 10 may also include a tension control knob or switch 64. The tension control knob 64 may be operably connected to the controller 62. The tension control knob 64 may be used, for example, to set a desired tension level to which the strap S should be tensioned. The tension control knob 64 may be located, for example, on a second end 65 of the housing 12, opposite to the first end 26, and may be recessed in the housing 12. In one embodiment, the second end 65 may be a rear end of the housing 12. Positioning of the tension control knob 64 as described in the example above may allow for ease of tension adjustment while maintaining the control knob 64 in a location that reduces the opportunity for inadvertently changing the tension.

The tool 10 may optionally include a plurality of other sensors operably connected to the controller 62, for example, one or more strap sensors or home position switches 68 or sensors as described in Figiel, et al., U.S. Patent Application Publication Number 2014/0060345, commonly assigned with the present application to Signode Industrial Group LLC of Glenview, Illinois, and incorporated herein by reference in its entirety.

In one embodiment, the tool 10 may include one or more strap sensors 66. The strap sensor 66 may be positioned in the tensioner head 20 or nosepiece 22 to detect or sense the presence or absence of the strap S in the strap feed path 46. The strap sensor 66 communicates with the controller 62 to allow the motor 16 to operate when the strap S is sensed by the strap sensor 66. In addition, the strap sensor 66 may be used as an alternative to the trigger 60. That is, upon sensing or detecting the strap S in the strap feed path 46, the strap sensor 66 may communicate a signal to the controller 62 to power the motor 16 to drive the tension feed wheel 40 and tension the strap S. The strap sensor 66 may be, for example, a retractable sensor positioned in the strap feed path 46 that is retracted by the strap S when the strap S is positioned in the strap feed path 46.

The tool 10 may also include a home position switch 68 positioned in the tensioner head 20 or nosepiece 22. The home position switch 68 detects when the nosepiece 22 is or is not in a fully closed position, i.e., rotated completely in the first direction under the force of the biasing element 52. The home position switch 68 is in a first state when the nosepiece 22 is fully closed and there is no strap in the tool 10. In a second state, the nosepiece 22 is other than fully closed or the strap is positioned in the strap feed path 46.

The home position switch 68 can be actuated by a home switch contact member (not shown). The home position switch 68 changes state when the home switch contact member contacts the home position switch 68 or moves out of contact with the home position switch 68. The tool 10 may also include an operating lever position switch 72 located on the housing 12 that is actuated (or changes state) when a finger or like element 74 on the operating lever 24 contacts the switch 72.

As noted above, the tool 10 may function in an automatic operating mode or a manual operating mode. In automatic mode, according to an embodiment described herein, the tool 10 may be initially positioned with the load engaging surface 44 in flat contact with a flat side of a package to be bundled. The nosepiece 22 is fully closed, i.e., rotated in the first direction under the force of the biasing element 52, on the tensioner head 52 and the home position switch 68 is in a first state. The operating lever 24 is moved to rotate the nosepiece 22 relative to the tensioner head 20, or vice versa, in the second direction to open a gap between the tension feed wheel 40 and clutch plug 48. Moving the operating lever 24 moves the home switch contact member off of the home position switch 68, thereby changing the state of the switch to a second state to allow the tool 10 to enter the tension cycle. That is, changing the state of the home position switch 68 generates a signal to the controller 62 that allows the motor 16 to start.

Further pulling the operating lever 24 engages the finger 74 on the operating lever 24 with the operating lever position switch 72 which changes the state of the operating lever position switch 72 and generates a signal to the controller 62 to “wake” the tool 10 from a sleep mode (e.g., when not in use for a period of time, the tensioner 10 goes into a “sleep” or low power mode to conserve power and battery life).

Overlapping ends of the strap, i.e., the leading end portion L and trailing end portion T, which were previously positioned around the load, are then positioned in the strap feed path 46 of nosepiece 22 between the tension feed wheel 40 and the clutch plug 48. The clutch plug 48 is positioned proximate to the leading end portion L such that the friction surface of the clutch plug 48 is configured to engage the leading portion L and the tension feed wheel 40 is configured to engage the trailing end portion T upon rotation of the nosepiece 22 in the first direction to the closed position. The strap sensor 66 senses the presence of strap in the strap path and generates a signal to the controller 62.

The operating lever 24 is then released to close the nosepiece 22. As the nosepiece 22 closes, i.e., is rotated in the first direction under the force of the biasing element 52, the home position switch 68 remains in the second state. The overlapping plies L, T of the strap S are held or clamped between the tension feed wheel 40 and the clutch plug 48 under opposing compressive forces from the tension feed wheel 40 and the clutch plug 48. The clutch plug 48, and in particular, the friction surface of the clutch plug 48 engages the leading end portion L to substantially hold the leading end portion L against movement along the strap feed path 46 while the tension feed wheel 40 engages and drives the trailing end portion T.

With the home position switch 68 in the second state, and the strap sensor 66 sensing strap in the strap feed path 46, the controller 62 sends a signal to the motor 16 to commence the tension cycle. The controller 62 can be configured to include a slight delay (e.g., 5 seconds) between the time the finger 74 disengages from the operating lever position switch 72 and the strap sensor 66 senses the presence of strap S, and when the motor 16 starts. The motor 16 then drives the tension feed wheel 40 to feed the trailing end portion T of the strap through the strap feed path 46, sliding the trailing end portion T relative to the leading end portion L (held stationary by the clutch plug 48), to tension the strap S around the load.

Alternatively, in some embodiments, the user may actuate the trigger 60 to begin the tension cycle. Actuation of the trigger communicates a signal to the controller 62. Upon receipt of the signal from the trigger 60 to begin the tension cycle, the controller 62 confirms receipt of the signals from the strap sensor 66 and home position switch 68. The controller 62 then operates the motor 16 in response to receipt of the signals from the strap sensor 66, home position switch 68 and trigger 60.

As tension increases, the current drawn by the motor 16 increases. When a preset current is reached (which corresponds to reaching a predetermined tension), the controller 62 signals the motor 16 to stop and the tension cycle is complete. A seal C may then be crimped on the overlapping portions of strap S. The controller 62 may be configured to reverse the motor 16 by, for example, holding the trigger 60 (or depressing the trigger 60 for a period of time longer than to initiate operation), which signals the controller 62 to reverse the motor 16 direction.

Upon completion of the tensioning cycle and sealing of the strap S, the tool 10 may be removed for the strap, The operating lever 24 may be rotated to open the nosepiece 22 such that the tension feed wheel 40 and clutch plug 48 are moved away from another and substantially disengage the leading and trailing portions of the S. Accordingly, the tool 10 may be removed from the strap S. The home position switch 68 contact member may engage the home position switch 68, to reset the operating program (the controller 62), which then allows the tool 10 to reenter the tensioning cycle if all of the operating conditions are met (e.g., a subsequent positioning of strap S between the tension feed wheel 40 and the clutch plug 48 and sensed by the strap sensor 66 and the finger 74 has engaged and subsequently disengaged from the operating lever position switch 72). It is understood the present disclosure is not limited to the embodiments above. The tool 10 may include all of or only some of the sensors or switches described above, and the steps included in the automatic operating mode may be adjusted accordingly. For example, some sensors or switches may be omitted where the functionality of the sensor or switch may be performed manually.

The manual operating mode includes operations similar to those in the automatic operating mode, except the steps are carried out manually. For example, according to an embodiment, the operating lever 24 is rotated to rotate the nose piece 22 in the first direction and move the tension feed wheel 40 and clutch plug 46 away from another so that overlapping plies of the strap S, i.e., the trailing end portion T and leading end portion L, may be received in the strap feed path 46. A load engaging surface 44 is positioned in contact with load or package. The operating lever 24 may be released to rotate the nosepiece 22 in the first direction so that the tension feed wheel 40 engages one ply of the strap S and the clutch plug 48 engages the other ply. Positioning of the strap S in the strap feed path 46 and the position of the nosepiece 22 may be manually verified. The trigger 60 may then be actuated to power the motor 16 to drive the tension feed wheel 40, and in turn, tension the strap around the load. Actuation of the trigger 60 may power the motor 16 for a predetermined amount of time or until a user indicates a desired tension has been obtained (for example, by another actuation of the trigger 60).

Although the controller 62 is not required for operation in the manual operating mode, the controller 62 may be included and be operably connected to various sensors, for example, to determine when a desired tension has been obtained. In some embodiments, the tool 10 may be equipped to operate in the manual mode only.

As noted above, the trigger 60 can be used to change between operating modes, for example, between manual and automatic modes, and can be used to stop and reverse the motor 14 when the tensioner 10 is operating in either manual or automatic mode. The trigger 60 can include LEDs or the like that indicate the mode of operation, the status of the tool 10, fault modes/conditions, battery power and the like.

In addition, in the event that the tool 10 is stopped prior to the completion of a cycle, following removal and repositioning of the strap, the operating program (the controller 62) will reset, again, when all of the operating conditions are met, to allow the cycle to recommence when a subsequent section of strap is positioned between the tension feed wheel 40 and the clutch plug 46 and sensed by the strap sensor 66.

FIG. 6 is a perspective view showing a modular cutter 70 that may be removably attached to the nosepiece 22 of the tool 10 using suitable fasteners 76, such as screws or bolts. In one embodiment, the modular cutter 70 is positioned adjacent to the strap feed path 46 at a front end of the nosepiece 22. The modular cutter 70 may be manually or electrically actuated via, for example, the trigger 60 or another, separate actuator. In one embodiment, the cutter 70 may be controlled to engage and cut the strap S at the end of the tension cycle, after the strap has been tensioned and sealed.

The modular cutter 70 may include a cutter path 78 configured to extend substantially in line with the strap feed path 46 and receive a portion or overlapping portions of the strap S therein. The modular cutter 70 includes a cutting blade 80 configured to cut the strap. In one embodiment, the cutting blade 80 is actuated to move into and out of the cutter path 78 to cut the strap S. Additionally, in one embodiment, the cutting blade 80 moves substantially linearly perpendicular to the cutter path 78, but is not limited to such a configuration. For example, the cutting blade 80 may move substantially linearly into the cutter path 78 from non-perpendicular angles, or may be rotated into cutter path 78 to cut the strap S.

In one embodiment, the modular cutter 70 may be actuated manually by an actuator handle 82 operably connected thereto. In one embodiment, the actuator handle 82 may be pivotably connected to the modular cutter 70 and can be pivoted or rotated to drive the cutting blade 80 into and out of the cutter path 78 for cutting of the strap S. The actuator handle 82 may be connected to the cutting blade 80 by way of a suitable camming mechanism, for example.

Further, the modular cutter 70 may include a foot 84 having a load engaging surface 86. The foot 84 may bound at least a portion of the cutter path 78. For example, an upper surface of the foot 84 may form a lower boundary of at least a portion of the cutter path 78. In one embodiment, the load engaging surface 86 of the modular cutter 70 may be substantially planar and be disposed in a coplanar relationship with the load engaging surface 44 of the tension foot 42.

In the embodiments above, a strap S may extend around a load or package having a flat side. The load engaging surface 44 of the nosepiece 22 is substantially planar and engages a flat side of the package. A trailing end portion T and a leading end portion L of the strap S are positioned in a strap feed path 46 of the nosepiece 22 between the tension feed wheel 40 and the clutch plug 48 for tensioning about the load package. Accordingly, one portion of the strap S, for example, the leading end portion L, may be held substantially stationary by the clutch plug 48, while another portion of the strap S, for example, the trailing end portion T, may be driven by the tension feed wheel 40 to tension the strap S about the load. In these embodiments, a user is not required to hold one end of the strap against movement during the tensioning cycle. Further still, the tool 10 may operate in the tensioning cycle without a user holding or guiding the tool 10. For example, the tool 10 may be supported on a flat side of the load or package by the load engaging surface 44 and a rear portion of the housing 12, for example, a depending or base portion of the housing. That is, in some embodiments, once the tool 10 is positioned relative to the load or package with the strap S positioned in the strap feed path 46 and conditions are met to begin the tensioning cycle, the tool 10 may be self-supported so as to conduct the tensioning cycle without intervention or guidance from the user.

Accordingly, in the embodiments above, a tensioner tool 10 may be portable and can be used anywhere as needed, may be powered by an on-board source and may optionally operate through a manual or automatic tensioning cycle. The tool 10 may also include on-board tension control to more accurately control tensioning of a strap S and vary a desired level of tensioning for each use. Further, higher tensions may be achieved without a connection to an external power supply, e.g., via a pneumatic hose, or increased human strength. It is understood that various features from any of the embodiments above may be used together with or implemented into other embodiments above.

From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present disclosure. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover all such modifications as fall within the scope of the claims. 

What is claimed is:
 1. A tool for tensioning a strap around a load, the tool comprising: a housing having a gripping portion formed on an exterior surface; a power supply; a motor disposed within the housing and operably connected to the power supply; a tensioner head positioned at one end of the housing, the tensioner head having a drive shaft operably connected to and configured to be driven by the motor; a tension feed wheel mounted on and configured to rotate with the drive shaft; a nosepiece rotatably mounted to the tensioner head having a strap feed path configured to receive overlapping plies of a strap, the nosepiece comprising a tension foot having a substantially planar load engaging surface configured to engage a substantially flat surface of the load; a clutch plug secured to the tension foot, wherein a portion of the strap feed path is formed between the tension feed wheel and the clutch plug; a biasing element configured to urge the nosepiece in a predetermined direction relative to the tensioner head; and an operating handle coupled to the tensioner head and nosepiece, the operating handle configured to rotate the tensioner head and nosepiece relative to one another in a first direction against a force from the biasing element to increase a gap between the tension feed wheel and the clutch plug to receive overlapping plies of the strap.
 2. The tool of the claim 1, wherein the strap feed path is substantially parallel to the load engaging surface.
 3. The tool of claim 1, further comprising a powertrain disposed in the housing and interconnected between the motor and the tensioner head.
 4. The tool of claim 1, further comprising a side plate secured to the tensioner head.
 5. The tool of claim 1, further comprising a trigger to actuate the motor to drive the tension feed wheel.
 6. The tool of claim 1, further comprising a controller operably connected to the motor and configured to control the motor to selectively operate the tension feed wheel.
 7. The tool of claim 6, further comprising a tension control knob operably connected to the controller, the tension control knob configured to set a desired level of tension and communicate the desired level of tension to the controller.
 8. The tool of claim 6, further comprising a strap position sensor, operably connected to the controller, configured to detect the presence or absence of the strap in the strap feed path and communicate the presence or absence of the strap the controller.
 9. The tool of claim 6, further comprising an operating lever position switch operably connected to the controller and configured to detect movement of the operating lever to a predetermined position and communicate movement of the operating lever to the predetermined position to the controller.
 10. The tool of claim 6, wherein the trigger is operably connected to controller and is configured to change between different operating modes.
 11. The tool of claim 6, further comprising a home position switch operably connected to the controller, the home position switch configured to detect a position of the nosepiece and communicate a signal to the controller indicating the position of the nosepiece.
 12. The tool of claim 1, further comprising a strap guide positioned at a rear portion of the strap feed path, the strap guide having a tab configured to laterally guide and the maintain the strap under the tension feed wheel.
 13. The tool of claim 1, further comprising a module cutter secured to the nosepiece, the modular cutter having a cutting blade configured to cut the strap.
 14. A method of operating a tool for tensioning a strap around a load, the tool comprising nosepiece having a tension foot with a substantially planar load engaging surface, the method comprising: receiving, at a controller, a first signal from a strap sensing sensor that a strap is positioned in a strap feed path of the tension foot; receiving, at the controller, a second signal from a home position switch indicating that the home position switch has changed from a first state to a second state; and operating, by the controller, the motor to drive a drive shaft and rotate the tension feed wheel to tension the strap around the load in response to receipt of the first and second signals.
 15. The method of claim 14, further comprising receiving, at the controller, a predetermined tension level from a tension control knob.
 16. The method claim 15, wherein operating the motor further includes operating the motor until the predetermined tension has been reached.
 17. The method of claim 14, wherein operating the motor further includes operating the motor for a predetermined length of time.
 18. The method of claim 14, further comprising receiving, at the controller, a third signal from an operating lever position switch indicating movement of an operating lever, and the operating of the motor further includes operating the motor in response to receipt of the third signal.
 19. The method of claim 14, further comprising receiving, at the controller, a tension cycle start signal from a trigger, and operating of the motor further includes operating motor in response to receipt of the tension cycle start signal.
 20. A nosepiece for a strap tensioning tool having a housing, a power supply, a motor disposed in the housing, a tensioner head having a drive shaft and a tension feed wheel mounted on the drive shaft, the nosepiece comprising: a pivot pin configured to rotatably couple the nosepiece to the tensioner head; a tension foot having a strap feed path configured to receive overlapping plies of a strap and a substantially planar load engaging surface; and a clutch plug positioned in the tension foot substantially opposed to the tension feed wheel, the clutch plug configured to engage a strap to be tensioned. 